TS 250 
.S7 
1920 
Copy 1 



SHEET METAL 
PRIMER 




i 



SHEET METAL 
PRIMER 




REVISED EDITION 



Copyright 1915-1920 

THE STARK ROLLING MILL CO. 
Canton, Ohio 

Form 89rA— 10-20— 2SM 



T5a5o 
■57 



:,i 27 iS20, 
§)CU604724 



I 



LESSON I 
IRON ORE 

RON ORE is a reddish-brown mineral, found in both a 
granular and rock-like form. 



It is very seldom found pure. Usually it is full of earthy 
matter and very impure. 

The most common impurities and the most harmful to the 
finished material, when present in excess, are Carbon, Sulphur, 
Phosphorous, Manganese and Silicon. 

The largest iron ore deposits in this country are in the 
Lake Superior district. 

In the Lake Superior district the ore lies near the surface 
of the earth and can be cheaply mined with large steam 
shovels. 



In less favored districts shafts must be sunk and the ore 
mined and brought to the 
surface by elevators. 



The ore is loaded into 
large boats which take it 
to the great blast fur- 
naces. 




IRON ORE READY TO BE 
SHIPPED 



LESSON II 
THE BLAST FURNACE 




W 



HAT is a Blast Fur- 



nace .'' 



A BLAST FURNACE 



A Blast Furnace 
is a huge cylindrical steel 
shell, lined throughout with 
fire brick and varying in 
height from forty to one 
hundred feet, or even higher. 



It is used to separate iron ore from earthy matter and part 
of the impurities. 

The Blast Furnace eliminates only a very small part of the 
impurities, as the Blast Furnace process is really the first step 
in making a useful material from the iron ore. The metal is 
further refined by other processes. 

Each Blast Furnace is connected with four stoves. These 
stoves are huge cylindrical tanks of steel about as high as the 
Blast Furnace itself. 



After the fire brick linings in the stoves are heated to a high 
temperature air is blown into them to be heated. 

When this air is intensely hot it is blown, by immense 
engines, into the blast furnace which is filled to the top with 
alternate layers of iron ore, limestone and coke. 



Thus, the iron ore is reduced first to a spongy mass, and 
then to a liquid state. 

It is the duty of the limestone to combine with the earthy 
matter and impurities and leave the molten iron free. 

The limestone and earthy matter is called "slag." The slag 
rises to the top and is run off. 

The molten iron is released from the Blast Furnace by 
drilling through the tap hole with a heavy pointed steel bar. 

From one hundred to one hundred and fifty tons of liquid 
iron flow through this tap hole, carrying with it about 
twenty-five or thirty tons of slag which could not be removed 
from the top. 



This slag is removed from the iron by a "skimmer," which 
is an iron plate extending 
down almost to the bottom 
of the trough. The molten 
iron flows under the "skim- 
mer" and the lighter slag is 
diverted into another run- 
ner. 

The iron is cast in molds 
and the product called Pig 

T-rt„ TOP OP BLAST FURNACE 

"°"* SHOWING METHOD OF FILLING 







t 




1 



w 



LESSON III 
PIG IRON * 

HAT is Pig Iron? 

Pig Iron is the reduced iron produced by the Blast 
Furnace. 



As the molten iron comes from the Blast Furnace it is run 
into molds or distributed into brick lined ladles mounted on 
wheels and sent on to the next refining process — ^the Open 
Hearth Furnace or the Bessemer Convertor. 

The advantage of casting the iron into molds, or "pigs" is 
that it can be stored away for future use. 

Two methods are used for casting Pig Iron — one is by ma- 
chine and the other is by casting in sand. 

The method of casting pigs by machine is a great improve- 
ment over sand casting. It is not so hot for the workmen and 
it produces pigs which are cleaner and free from sand. 



Many blast furnaces 
still use the sand-casting 
method. 

Pig Iron is really a raw 
material and cannot be 
rolled directly into sheets 
without further refine- 
ment. 




PIG IRON 



T 



LESSON IV 
THE BESSEMER PROCESS 

HE Bessemer Process for making Steel is named after 
one of its inventors, Sir Henry Bessemer. The Steel 
is called Bessemer Steel. 



Bessemer Steel is made in a converter. 

A converter is a pear shaped retort with a large number of 
holes in the bottom. 

The molten pig iron is poured into the converter and a 
powerful blast of air is blown through the holes in the bottom. 

This air enters and passes through the molten metal, liter- 
ally burning out the impurities. The gaseous impurities go 
out of the mouth of the converter in the shape of sparks and 
flames, while the solid impurities go into the slag. 

The process lasts about twenty minutes and the operation is 
controlled by a man called a 
"blower." 



A slower and more thorough 
method for making steel sheets 
was invented soon after the in- 
vention of the Bessemer Process. 
This was called the Open Hearth 
Process for making steel sheets, 
which is described in the next 
lesson. 




THE BESSEMER CONVERTOR 



Lesson v 
open hearth furnace 



W 



HAT is an Open Hearth Furnace? 

An Open Hearth Furnace is the retort where the iron 
goes through its final refining process. 



The Open Hearth Furnace is entirely different in appear- 
ance and operation from the Blast Furnace. 

It looks very much like a huge oven. Usually several fur- 
naces are built together in a single row, and are constructed 
of fire-brick and steel. 

There are two kinds of Open Hearth Furnaces — the Basic 
Open Hearth and the Acid Open Hearth. The difference lies 
in the lining and each furnace produces different classes of 
material. 



For some purposes the Basic Open Hearth Furnace is the 
best while for other pur- 
poses the Acid Open 
Hearth Furnace is better 
suited. 



The Open Hearth Fur- 
nace is so called because 
the hearth or bottom of 
furnace is exposed to the 
action of the flame above. 



iniHJI 


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A ROW OF OPEN HEARTH 
FURNACES 



LESSON VI 
THE INGOT 

AFTER the metal is thoroughly refined in the Open 
/"^^ Hearth Furnace or Bessemer Convertor, it is poured 
directly into a huge ladle, and from there into large 
rectangular molds, called "Ingot Molds." 

The metal is permitted to harden in the molds, after which 
the molds are stripped off and the immense rectangular 
shaped piece of metal is called an "Ingot." 

An Ingot weighs from one thousand to eight thousand 
pounds. 

This immense piece of metal is handled entirely by ma- 
chinery. An electrically operated "stripper" removes the 
Ingot Mold from the Ingot and the Ingot is lifted by a travel- 
ing crane and carried on to the 
soaking pit. 



The soaking pit is a furnace be* 
low the floor level into which the 
Ingot is lowered to be reheated 
before rolling. 

Gases, causing blow holes, and 
impurities rise to the top of the 
Ingot. Therefore, the upper por- 
tion of the Ingot is cut off before 
rolling. 



■■fflHnr""<""fiannrT m\ i ^ 



STRIPPING THE MOLDS 
FROM THE INCOT*^ 



LESSON VII 
BLOOMING MILL 



THE Ingot after being reheated to the proper tempera- 
ture receives its first actual working in the blooming 
mill, which consists of a pair of heavy steel rolls, 
placed one above the other, clothes wringer style. 

The drive is so designed that the direction in which the 
rolls are turning can be almost instantly reversed and the in- 
got can be passed either forward or backward through the 
rolls as the operator may desire. 

The entire operation of the mill is controlled from an 
"operating pulpit" similar to the "bridge" of a battleship. 

This "pulpit" is equipped with a very ingenious series of 
control levers by means of which the operators can control the 
speed and direction of the driving motor, regulate the distance 
between the rolls by raising or lowering the top roll, and 
operate a set of giant fingers, known as "manipulators," which 
turn the ingot over or shift it to any desired position in front 
of the rolls. 



The ingot passes forward and 
backward between the rolls. 
Between passes, the operator 
turns the ingot, by means of the 
manipulators, so that it is thor- 
oughly worked on all four sides 
and he also regulates the dis- 
tance between the rolls in such 
a manner that after each pass 
the ingot is reduced in width 
and thickness and increased in 
length and is finally converted 
into a semi-finished piece called 
a "bloom." 




THE BLOOMING MILL 



10 



A 



LESSON VIII 
THE BAR MILL 

S mentioned in Lesson VII, the blooming mill con- 
verts the ingot into a semi-finished piece called a 
"bloom." 



The metal is still very hot and without reheating, it is 
shifted across the building, by means of a transfer table, to a 
position in line with the sheet bar mill. 

The ends of the bloom are ragged and in addition to this the 
end which was originally the top of the ingot is apt to contain 
segregated impurities, so this defective metal is cropped off 
by means of a powerful shear. 

From the bloom shear, the ingot enters the continuous sheet 
bar mill. 

This mill consists of a number of stands of rolls placed in a 
tandem arrangement, so that the metal passes continuously 
from one stand to the next. The rolls in each stand are ad- 
justed so that the bar is reduced in width and thickness and 
increased in length after going through each successive stack 
of rolls and the bar will be the desired gauge or foot weight 
when it leaves the finishing pass. 

The bar is taken away from the mill on a table equipped 
with power driven rollers and passes through the "flying 
shears" where it is cut into thirty-foot lengths without stopping 
the bar. The bars then pass to the cooling beds from which 
they are transferred to the stock piles or to cars for shipment 
to the sheet mills. 




CROSS SECTION OF BAR MILL 

Showing the reduction in the thickness of the bar as it passes through each stack 
of rolls. 

11 



LESSON IX 
SHEET ROLLING MILL 



THE sheet rolling mill also resembles a clothes wringer. 
The rolls are made of special chilled iron and revolve 
constantly. 
The sheet bars are heated to the desired temperature in a 
large furnace. 

Usually two sheets are rolled at one time, except in the case 
of heavy sheets which can only be rolled one at a time. 

The "Roller" passes the bar through the rolls to the 
"Catcher" who passes it back over the top of the roll while 
the second bar is coming through between the rolls. This 
operation is repeated until a certain thickness is reached and 
then both partly finished sheets are placed on top of each other 
and rolled until cold. Then several partly finished sheets are 
placed together in a "pack," bent double and placed in the 
sheet furnace to be reheated. 

When sufficiently hot the entire pack is passed through the 
rolls until the desired thickness or gauge is reached. 

When cool enough to handle, the sheets are sheared in 
packs. 

The sheets are then separated by hand or with tongs. Fre- 
quently the sheets are stuck together so tightly that it is diffi- 
cult to separate them without using considerable force. 

In separating the sheets they become bent and crimped mak- 
ing it necessary to pass 
them through the "cold 
rolls." 

The cold rolling mill is 
very similar to the hot mill 
in appearance. The sheets 
are passed through the 
rolls without heating. This 
straightens out the sheets 
ROLLING THE SHBBTT ^nd improvcs the surface. 




12 



V 



LESSON X 
ANNEALING 

ERY few sheets are sold as they come from the hot 
rolls. They must be annealed first. 



The annealing process makes the sheet soft and ductile and 
removes any strains set up in the sheet by too rapid cooling. 

The sheets are piled up evenly on an iron base and covered 
with an iron box so that no air will reach them. 

This box, containing the sheets, is run into a large square 
oven and heated to about fourteen hundred or sixteen hun- 
dred degrees, which requires about sixteen or twenty hours. 

By means of mechanical devices the heat can be carefully 
regulated and the cooling process started at just the right 
time. 



When the sheets are annealed the annealing box is removed 
from the annealing oven but the sheets are not uncovered 
until they have cooled to exactly the right degree. Oxygen 
must be prevented from 
reaching the sheets during an- 
nealing or cooling to prevent 
scale forming. 

This process requires great 
skill and care. 

The sheets are now ready 
for use, unless a galvanized 
coating is desired. annealing box 




13 



c 



LESSON XI 
GALVANIZING 

GATING sheet metal with hot zinc is called "Galvan- 
izing." 



A metal sheet is galvanized as a protection against rust and 
corrosion ; for appearance ; and to make soldering of the sheet 
possible. 

The sheets are first "pickled;" that is, placed in an acid 
bath to clean the surface thoroughly. Then they arc washed 
in water. 

Just before galvanizing the sheets are run through a Sal 
Ammoniac solution, which helps the hot zinc stick to the sheet. 

The sheet is galvanized by passing it through a "galvaniz- 
ing pot" or large square iron tank filled with molten zinc, or 
spelter. This is all done 
by machinery. 



The galvanized sheet 
has a silvery grey, 
spangled appearance. 

The metal sheet is now 
ready for use. 



■ liii.:':::!!!!!!ii|nillllllli 




GALVANIZING SHEET METAL 



14 



T 



LESSON XII 
TONCAN METAL 

ONCAN METAL is a sheet metal made from iron 
ore. 



But it is different from any other sheet metal because it is 
rust and corrosion-resisting. 



Years ago when Toncan Metal was first produced its ability 
to combat corrosion was doubted by many. Today it cannot 
be doubted or disputed because Toncan Metal in actual serv- 
ice for years has proved beyond the shadow of a doubt its 
wonderful rust and corrosion-resisting properties. This evi- 
dence can be procured on request. 



The principal reasons for Toncan MetaFs durability are 
homogeneity, purity, careful selection of raw materials and 
scientific methods of production. This is fully explained in 
the lessons that follow. 



In spite of the fact that Toncan Metal will outlast any 
sheet metal made from iron 
ore it costs less than so- 
called charcoal iron and only 
a trifle more than steel 
sheets. 



Toncan Metal forms 




GALVANIZED TONCAN METAL 
SHEETS 



15 



easily without breaking and welds excellently by any 
process. 

Galvanized, black or blue annealed Toncan Metal can be 
procured. 

Toncan Metal is used for all purposes where sheet metal 
can be used, for instance — 

For building construction — Toncan Metal Roofing, Siding, 
Eaves Trough, Conductor Pipe, Ventilators, Cornice, Window 
Frames, Skylights, Lath and Water Tanks. 

For railroad work — Culverts, Box Cars, Passenger Cars, 
Car Roofs, Trestle Coverings, Brine Troughs and Refriger- 
ators. 

For road construction — Culverts. 



For miscellaneous purposes — Flumes, Silos, Grain Bins, 
Refrigerators, Signs, 
Garbage Cans, Stoves, ^^ 
Enameled Ware, Fur- 
naces, Washing Ma- 
chines, Gas Machines, 
Gas Holders, Brick 
Pallets and innumer- 
able other sheet metal 

products. TONCAN METAL SHEETS READY 

TO SHIP 




16 



F 



LESSON XIII 
THE REASON WHY 

OUR thousand years ago iron and steel sheets were 
made that lasted for years and years. Evidence of this 
has been found by scientists. 



Research has revealed crude furnaces and tools which were 
used at that time for iron making. 

And pieces of iron and steel have been found that were 
made four thousand years ago and are still in good condition. 

Because of their crude facilities and methods they worked 
very slowly. Two men made about a dozen pounds of iron a 
day. And for that reason they could watch every detail. 

The analyses of these ancient pieces of iron and steel show 
that they contain only a very slight percentage of impurities 
and that whatever impurities are in the material are in proper 
proportion, evenly and uniformly distributed — or, in other 
words, the metal is "homogeneous." 

This proved that many things were known about iron and 
steel making in those days that we knew nothing about. The 
art was lost. 



And when more durable sheet metal than steel and iron was 
demanded prominent scientists investigated. 

17 



After years of hard work and careful research they learned 
(first) why modern steel and iron sheets corroded and (sec- 
ond) why the sheet metal four thousand years ago was so 
durable. 

They found that modern sheet metal was short-lived be- 
cause it was impure, non-uniform in structure (non-homoge- 
neous) and made carelessly, too rapidly and unscientifically. 

And they learned that the old time sheet metal was so dur- 
able because it was pure, uniform in structure (homogeneous) 
and made carefully, slowly and scientifically. 

The greatest task was to determine a method for making a 
sheet metal in a modern furnace that would be equal to the 
sheet metal of four thousand years ago — and still keep the 
cost low. 

This, too, was finally accomplished. 

A metal sheet was evolved that could resist the ravages of 
the most severe corrosive 
influences; a sheet that 
could be worked, formed 
up, bent and seamed; a 
sheet that could be 
bought by the ultimate 
consumer at a low price. 

Its makers called it 
"Toncan Metal." 

IN THE LABORATORY 




18 



As the good properties of Toncan Metal became known, it 
created new uses for sheet metal. Products that heretofore 
had been made of other materials, because sufficiently durable 
sheet metal could not be procured at a moderate cost, are being 
made today of Toncan Metal. 

The old time iron sheets were durable, it is true, but to 
combat the smoke, fumes, gases, soot and cinder which fill the 
air today even more durable sheet metal is needed. And Ton- 
can Metal has been found to withstand these conditions to a 
degree hitherto considered impossible in an iron ore product. 

The sheet metal worker, user, manufacturer, architect and 
contractor welcomed Toncan Metal with open arms. At last 
it was possible to procure sheet metal that would give pro- 
longed service at a comparatively low cost. It is indeed a 
"happy medium" between durable, but extremely expensive 
sheet metal, and cheap, but short-lived sheet metal. 

Science had revived the sheet metal of four thousand 
years ago. A lost 
art was found. r# ef^r^ #\r /'m\^^^ 



Now let us see 

TONCAN METAL CAN BE FORMED. BENT 
V,««7 +Viic «rac r^riTiA AND SEAMED WITHOUT BREAKING 

how this was done. (Drawn from a photograph) 



19 



LESSON XIV 
RUST AND CORROSION 

IRST, we must know that rust and cor- 
rosion are different and why they are dif- 
ferent. 

Rusting is a natural process and can- 
not be prevented. It is nature's method 
of returning iron products to their orig- 
inal state — iron oxide. Just as man re- 
turns to clay. 



And just as man with a strong consti- 
tution will outlive the weak man, so properly made sheet 
metal will outlast carelessly and unscientifically made sheet 
metal. 

Corrosion is different — it is a disease. 

First — a reddish-brown spot appears. The spot spreads. 
The sheet metal flakes off. Pin-holes appear. The holes 
grow larger. Slowly the sheet crumbles away and finally 
nothing is left. 




That's corrosion — the destroyer of sheet metal, 
the weakest sheet metal in its weakest spots. 

Toncan Metal is anti-corrosive. 



It attacks 



Toncan Metal will rust, however. It must rust because it 
is an iron ore product. No iron ore product has yet been in- 
vented that will not rust. 



But Toncan Metal will resist rust better than any other 
sheet metal made from iron ore. 



The coating of rust on Toncan Metal is uniform — no pitting, 
scaling or flaking off — no holes, for that would be corrosion 
and Toncan Metal is anti-corrosive. 

If a method were devised for preventing tuberculosis in the 
human race, it would be no more wonderful than Toncan 
Metal, which conquered the "white plague" of sheet metal — 
corrosion. 

For corrosion is truly a plague — a disease which lays to 
waste thousands and thousands of tons of iron ore products 
every year. 

The question is often asked "What will happen when our 
natural supply of iron ore gives out?" 

Trees can be planted to take the place of those used up for 
lumber and paper making, but the iron ore which is used up 
can never be replaced. 

So, we must use the iron ore which nature has given us in 
the most careful manner. We must reduce the corrosion of 
iron ore products. 

Toncan Metal is a great factor in saving our supply of 
iron ore for future generations because of its wonderful rust 
and corrosion-resisting properties. 

21 



LESSON XV 
PURITY AND HOMOGENEITY 

WE have learned that sheet metal corrodes because it 
is impure, non-uniform in structure (non-homoge- 
neous) and made carelessly, too rapidly and un- 
scientifically. 

What are the impurities? What is meant by "Purity"? 
And what is meant by "Homogeneity"? 

The impurities commonly found in iron ore products and 
dangerous when in excess are Carbon, Manganese, Silicon, 
Phosphorous and Sulphur. 

On the next page is shown the relative proportion of the 
different impurities in steel. 

Manganese in proper proportion to the other elements and in 
proper quantity is valuable but when present in excess and not 
in correct proportion it is dangerous. 

Sulphur in excess also causes the metal sheet to corrode. 
Besides it causes the sheet to crack and tear while rolling. 

Carbon gives the sheet strength, but too much carbon makes 
bending and forming difficult. 

Too much Phosphorus makes sheet metal brittle. 



Traces of Silicon are always present in all iron products. 

Compare the amounts of impurities in Steel with those in 
Toncan Metal as shown on the next page. 

When these impurities group together in different portions 
of the material they ''disagree." 

An action is started, similar to the action in the electric 
battery. In fact this action is known as "electrolysis." 

When this happens, the sheet metal decomposes, or cor- 
rodes, in spots, as explained in Lesson XIV. 

You understand that all the elements mentioned above are 
always present in iron. Each has its proper function and 
when present in the right proportion and correct quantity it 
adds to the value of the iron but if the quantity and proportion 
are not right the result is harmful instead of beneficial. 

No sheet metal can be one hundred per cent pure. 




RELATIVE PROPORTION OF IMPURITIES IN STEEL 

23 



Toncan Metal is made as near one hundred per cent pure as 
it is possible to make sheet metal fron\ iron ore. 

Toncan Metal is made to that degree of purity which gives 
the best results. 

However, the wonderful rust-resisting qualities of Toncan 
Metal are due also to the proper proportion and distribution of 
all elements so that excessive quantities are not present at one 
or more points. 

This is called "making the metal homogeneous." 

Homogeneity is absolutely necessary. 

A pure sheet metal that is not homogeneous is not rust- and 
corrosion-resisting. 

Toncan Metal is both, homogeneous and pure. 

Purity and Homogeneity are two important factors in mak- 
ing Toncan Metal the most durable sheet metal made from 
iron ore. Other factors are also necessary which are men- 
tioned in the next lesson. 




RELATIVE PROPORTION OF IMPURITIES IN TONCAN 
METAL 



24 



Lesson xvi 
making toncan metal 




T requires at least four weeks to make a Toncan 
Metal Sheet. 

An ordinary metal sheet can be made with- 
in a week. 



In making Toncan Metal every detail is carefully watched 
-nothing is hurried. 



To begin with, the iron ore for Toncan Metal is carefully 
selected — not from any one mine, but from mines all over the 
country. Only the most desirable ore is used. 



As the material goes through some of the processes of 
which we learned in the beginning, it is given special scien- 
tific treatment. 



Special mill practice is used in making Toncan Metal, and 
special crews of men make it — men who have had many years 
experience in sheet metal making. 



Analyses and inspections are made at different stages of pro- 
duction to insure material that is up to the established stand- 
ard of quality. The result is what might truly be called a 
perfect sheet metal. 



25 



It costs considerably more to make Toncan Metal than its 
moderate selling price indicates. 

In the first place, the higher grades of ore cost more than the 
inferior grades. 

Secondly — the special heat treatment and other scientific 
processes through which Toncan Metal is placed mean an ad- 
ditional expense. 

Third — the long continued refining process at an exception- 
ally high temperature reduces the life of the furnace linings, 
making frequent replacements necessary. 

Compare the methods used in making Toncan Metal with 
the production of steel or so-called iron sheets which are liter- 
ally shot through the various processes. Compare the four 
weeks required to make Toncan Metal with the one week for 
steel. 



Is it any wonder that Toncan Metal is so durable? Purity 
is only one factor. For years the manufacturers of Toncan 
Metal have worked on the foundation of purity, homogeneity, 
proper processes and proper temperatures until Toncan Metal 
became the best possible metal that could be produced. 

Are the manufacturers satisfied with the results secured? 
No. In the future Toncan Metal will have the benefit of any 
change in process, any addition in alloy, or any other factor 
that will improve it. 



LESSON XVII 
A FEW USES FOR TONCAN METAL 




ROOFING AND SIDING 



EAVES TROUGH. SKYLIGHTS, CORNICE 

CONDUCTOR PIPE AND VENTILATORS 

AND SHINGLES 







WATER CULVERTS 

TANK 




FLUME 



SILO 




In 


IF 


^=41 


n^ 


111"" 




BOX CAR 



TRESTLE AND REFRIGERATOR 

TIE COVERINGS 



WASHING 
MACHINE 



This trade mark <f5NCA^> on every sheet 



27 



s 



LESSON XVIII 
A PITFALL ' 

TANDARD gauge" is a meaningless term. 



At one time twenty-eight gauge was known as "stand- 
ard gauge." Then, when lighter gauge was demanded 

by some users, twenty-nine gauge was called "standard 

gauge." 

Today, if a man orders "standard gauge," he may get any- 
thing from twenty-eight gauge to even lighter than twenty- 
nine gauge. And yet pay for twenty-eight gauge. 

It is evident, therefore, that the term "standard gauge" is 
a dangerous one and should not be used by any buyer who 
wants full value for his money. 

The safest way to order sheet metal, either flat or formed, 
so as to avoid receiving lighter than twenty-eight gauge is to 
order Toncan Metal. 

Galvanized Toncan Metal is not made lighter than twenty- 
eight gauge. 

So when twenty-eight gauge Toncan Metal is specified the 
buyer is assured that he will get exactly what he pays for — 
twenty-eight gauge. 

Therefore, the double-diamond Toncan Metal trade mark 
on every sheet and every formed product assures, not only 
durability and economy, but honest, full weight sheet metal. 

28 



PERTINENT QUESTIONS AND ANSWERS 

Question — Why is Toncan Metal galvanized? 

Answer — For appearance and double protection just as a 
good piano is veneered and polished — a good automobile 
enameled — a good ship painted. But, it must be remembered 
that Toncan Metal does not depend on the galvanized coating 
alone for its durability. The durability chiefly lies in the metal 
itself. 

Question — Why is Toncan Metal not guaranteed? 

Answer — Toncan Metal does not require a guarantee any 
more than copper, zinc or nickel. The durability of all these 
metals is proven and Toncan Metal through its many years of 
service has proven its extreme durability also. The evidence 
can be procured from its manufacturers or any Toncan Metal 
jobber. Toncan MetaVs strongest guarantee is the fact that 
it needs no guarantee. 

Question — How can a buyer avoid the danger of receiving 
lighter than 28 gauge when he pays the price for 28 gauge? 

Answer — By specifying "28 gauge Galvanized Toncan 
Metal" the buyer is assured that he will receive no lighter 
than 28 gauge because Toncan Metal is not made lighter. 

Question — Can Toncan Metal be welded? 

Answer — Yes. It welds excellently by any process. 

Question — Does Toncan Metal rust? 

Answer — See Lesson XIV. 



Question — Does manganese have any special value in the 

manufacture of sheet metal? 

• 

Answer — Yes, manganese in proper proportion and quan- 
tity is valuable as it neutralizes the bad effects of sulphur on 
the working qualities of the hot steel and facilitates rolling. 
An excess of manganese, however, has a harmful effect and 
lessens corrosion-resisting qualities of the metal. 

Special processes used in manufacturing Toncan Metal regu- 
late manganese to just the right point to secure only the re- 
sults which are desirable. 

Question — How can evidence of Toncan Metal's durability 
be procured? 

Answer — Photographs of buildings and other places where 
Toncan Metal has been in use for years are contained in a 
book entitled "Better Sheet Metal." This book will be 
sent on request free of charge by any jobber of Toncan Metal 
or by the manufacturers themselves. Evidence of actual serv- 
ice is the best test for any material. It shows at a glance what 
would otherwise require years to determine. 

Question — Why should a dealer be anxious to sell and use 
Toncan Metal? 

Answer — The housewife patronizes the grocer, butcher, 
milliner and other dealers who give her goods of just a little 
better quality than she actually expects. And her husband 
does likewise. It's human nature. By recommending and us- 

30 



ing Toncan Metal, the sheet metal man gains the customer's 
confidence and gratitude. And the advertisement he receives 
when his customer tells his friends, relatives and neighbors 
helps to increase his business and profits. 

Question — Why should an architect specify Toncan Metal? 

Answer — Before the advent of Toncan Metal, an architect 
had nothing to offer the client who wanted a durable material 
at a low cost — nothing between high priced copper and cheap, 
short-lived steel or iron sheets. Toncan Metal is a "happy 
medium" and gives the user both durability and economy. 
See "Better Sheet Metal" for partial list of prominent archi- 
tects specifying Toncan Metal. 

Question — How are Toncan Metal Sheets and Formed Prod- 
ucts identified? 

Answer — All Toncan Metal sheets are stencilled in red as 
follows : 



<rONCAN> 



REG. U.S. PAT. OFF. 



And all Toncan Metal Eaves Trough, Conductor Pipe, El- 
bows, Shoes, Cut-offs and Mitres should bear the following 
die stamped inpression : 







MAKERS NAME 



31 



ADDENDA 

As the Primer is very elementary in character and devoted 
primarily to the description of the processes necessary for the 
production of sheet metal, we have added the "Iron and Steel 
Metallurgy in Brief." This gives a brief but comprehensive 
list and definition of the various general terms and processes 
used in the entire iron and steel industry. For the use of this 
summary we are indebted to the courtesy of the publishers of 
the Steel and Metal Digest. 

IRON AND STEEL METALLURGY IN BRIEF 
From Ore to Finished Product 

Iron Ore — Contains Iron and Oxygen and impurities. 
Smelted in Blast Furnace, removing Oxygen and 
part of impurities and adding Carbon, makes.— Pig Iron 

Foundry Pig Iron — Melted in Cupola and cast 

makes Iron Castings 

Iron Castings — Made from Malleable Pig Iron and 

heated in Scale, make Malleable Castings 

Grey Forge Pig Iron — Melted in a Puddling Furnace, 

then balled, squeezed and rolled, makes Muck Bar 

Muck Bar — Or Wrought Scrap cut into short lengths, 

piled, heated and rolled, makes Wrought Iron 

Muck Bar — Treated as above and rolled into strips, 

miakes Skelp Iron 

Skelp Iron — Bent into the shape of tubes and welded, 

makes Iron Pipe 

Muck Bar — Or Steel melted in a Crucible with Char- 
coal, makes Carbon Steel, Tool Steel or ....Crucible Steel 

Bessemer Pig Iron — Direct from Blast Furnace or 
melted in Cupola, poured into Convertor, with 
air blown through it to bum out the impurities 
makes Bessemer Steel 

Pig Iron — Molten, or in pig, with or without Scrap, 
when purified in Open Hearth Furnace makes 
Open Hearth Steel 

Low. Phos. Pig Iron — Treated as above in an acid (Sil- 
ica or Sand) lined furnace makes Acid O. H. Steel 

32 



Basic Pig Iron — Treated as above in a basic (Dolomite) 
lined furnace to remove Phosphorus makes 
^ Basic O. H. Steel 

Pure Iron — The product of a Basic Open Hearth fur- 
nace refined to a point where the impurities are 
reduced to the least practicable minimum is 
Toncan Metal 

Toncan Metal — Is poured into ingot molds making Ingots 

Ingots — Are rolled into Blooms or Billets 

Ingots — Are rolled into Slabs 

Blooms — Are rolled into Rails 

Blooms — Are rolled into Structural Shapes 

Slabs — Are rolled into Plates 

Billets — Are rolled into Bars and small shapes 

Billets— Are rolled into Steel Skelp 

Billets — Are pierced, rolled and drawn through dies, 

making Seamless Tubes 

Billets — Are rolled into Rods 

Steel Skelp — Bent into the shape of tubes and welded 

makes Steel Pipe 

Rods — Are drawn through dies into Wire 

Rods — Are headed into Rivets and Bolts 

Rods — Are welded into Chain 

Wire — Is made into Nails and Fencing 

Ingots — Are rolled into Sheet Bars 

Sheet Bars — Are rolled into Black Sheets 

Black Sheets — Cleaned, cold rolled coated with Tin 

makes Tin Plate 

Black Sheets — Cleaned, cold rolled coated with Lead 

and tin makes Terne Plate 

Black Sheets — Cleaned, cold rolled and coated with 

Spelter (Zinc) makes Galvanized Sheets 

All Sheets — Can be stamped into Various Forms 



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